ultratech cement limited -...

Sewagram Cement Works

UltraTech Cement Limited

(Unit: Sewagram Cement Works-Power Plant)

Welcomes all

On 18th National Award for Excellence in

Energy Management 2017

1


We are going to share…

Company Profile

Unit Profile

Plant Configuration and Flow diagram

List of ENCON Projects

Plant Performance over the years

Innovative Projects

Sustainability Initiatives

Methodology of Energy monitoring

Best practices/ Involvement of Employees

CSR initiatives

Awards & Accolades

Way forward


Selected as Superbrand 2011-12 by the Super brands council along

with Powerbrand awarded by the institute Power Brands India.

Company Profile

Star Brand India


One stop shop

for all

construction

needs of

Customer


Sewagram Cement Works (Acquired from Jaypee in June-14)

Clinker Capacity :3.6 mtpa(2X5500 TPD) & Cement Capacity – 2.4 mtpa

Captive power plants (CPP) CPP-I 35 MW & CPP-II 22.5 MW capacity.

Mines with reserve of 246.45 MT,

Captive jetty, a desalination plant that can filter around 20 lakh liters of water

every day

Unit At Glance


Power Plant Process Flow


Package Make Type Capacity &Feature

Boiler-1 TKIL CFBC 170TPH, Pr.-87 Kg/cm2, Temp.-

515 +/-50C

Boiler-2 IJT AFBC 110TPH,Pr.-87 Kg/cm2,

Temp.-515 +/-50C

Turbine-1 Siemens Condensing

35 MW, Pr.-84 Kg/cm2

Temp.-515 +/-30C, Steam Flow -

143.5TPH

Turbine-2 Siemens Condensing

22.5 MW, Pr.-84 Kg/cm2

Temp.-515 +/-30C, Steam Flow -

93.5TPH

Generator-1 &2 TDPS+Andritze Hydro Brushless

Excitation 11KV,43.75 & 28.125 MVA, PF-0.8

Coal &Lime stone

Handling Masyc Blow bar crusher

Coal-180TPH & Lime-60TPH, Flip

flow screen for High Moisture

coal

DG (03 Nos.) Man B&W 12.5MW +12.5MW +10.8MW

Desal Plant ION Exchange PTP + RO 6700 KLD

Broad Specification of TPP Equipments


List of ENCON Projects


SN Energy Saving Projects (01 No.)

Saving

Achieved

Electrical

Energy

(Rs. Lacs)

Saving Achieved

Thermal Energy

(Rs. Lacs)

1

Single ACW pump run against double ACW pump

operation for both TPP by throttling all I/L &

O/L valve of ACW line to each equipment to

optimum flow of ACW.

39.2

2

Optimization of service air and stoppage of one

Compressor (earlier running 02 compressor for

two Plants)

38.5

3 Stoppage of one PA fan of Boiler -2 by modifying

the start logic 14.5

Sub Total 92.2

Energy Savings Projects with No Investment Fy’14-15


SN Energy Saving Projects (06 Nos.)

Saving

Achieved

Electrical

Energy

(Rs. Lacs)

Saving Achieved

Thermal Energy

(Rs. Lacs)

1 Boiler -1 ID draft optimized at -15mmWC against -

25mmWC 2.3 -

2 Running of one BFP up to 80 % load for Both

Plant 191.1 -

3 Reduction of LOI from 10.5 to 4.5% 45.2

4 Further optimization of Instrument air pressure

from 6.5 kg/sq.cm to 6.0 kg/sq.cm 3.5 -

5 Operation of Boiler at Lower Bed Height i.e.

Reduction by 50MMWC. 87.1 -

6 Start Using of Pet Coke as alternate fuel to

improve Boiler Efficiency of Both TPP 12.9

Sub Total 284.0 58.1





Saving

Achieved

Electrical

Energy

(Rs. Lacs)

Saving

Achieved

Thermal

Energy

(Rs. Lacs)

1 Boiler-1&2 efficiency increase by optimize excess

O2 in flue gas at 3.9 % against 4.5 % 31

2 DM plant operation running hour optimized at 5

hrs./5 days against 2 hrs./day 1.4

3 For Boiler -1 &2, Lime screw feeder stop due to pre

mixing of lime in Coal conveyor belt 1.6

4 For Boiler -1 & 2, 10 Nos. Lime stone belt conveyor

stop due to pre mixing of lime in Coal conveyor belt 1

5 TG-1 Deaerator O/L temp. increased upto 155 Deg C

from 150 Deg C 2



Saving Achieved

Electrical Energy

(Rs. Lacs)

Saving Achieved

Thermal Energy

(Rs. Lacs)

6 Boiler -1 Bed ash cooler optimized running

hrs. to reduce PA fans power consumption 5.5

7 TG-1&2 Vacuum controlling through PID

controller 11.3

8

Cooling tower fan power consumption

optimized by PID controller of CW outlet

temperature to start of CT fan

3.1

9

Ash conveying air consumption optimized

by reducing nos. of hole of orifice from 12

to 6 reduce

0.1

10 All lights are stopped at CHP area in night

shift 2.1




Saving Achieved

Electrical Energy

(Rs. Lacs)

Saving Achieved

Thermal Energy

(Rs. Lacs)

11 Flue gas temp. of ESP I/L reduced from 135 to

130 Deg C looking to the sulphur due point 4.0

12

Service air compressor running Hrs. optimized

at 18 Hrs./day against 24 Hrs./day by

optimized operation of ash conveying system

8.6

13 Optimization of CHP running hours 4.7

14

Improvement of Boiler-2 Efficiency by

increasing Petcoke percentage by weight in

fuel mix from 7.3 to 40.2%

43

Sub Total 39.4 80

Grand Total 553.7



Energy Savings Projects with Investment Fy’14-15

SN Energy saving Projects (03 Nos.)

Saving Achieved

(Rs. Lacs)

Investment

(Rs. Lacs)

1 VFD installation in ACW pump with PID

controller 4.7 1

2

Hot well transfer pump running hours

optimization by modification of LP Heater drain

direct to flush tank

0.2 0.3

3 Replacement of conventional HPSV lights by LED

lights 2.4 4

Sub Total 7.3 5.3



Saving Achieved

(Rs. Lacs)

Investment

(Rs. Lacs)

1 Wet steam washing of TG-2 to improve

efficiency 34.8 5

2 Overhauling of TG-1 for Heat Rate improvement 599.8 85

3 Installation of VFD in TPP-2 CEP 10 4.3

4 Installation of VFD in TPP-1 CEP & PID

controller 19.3 4.3

Sub Total 663.9 98.6




SN Energy saving Projects (08 Nos.) Saving Achieved

(Rs. Lacs)

Investment

(Rs. Lacs)

1 AFBC high LOI ash used in CFBC to increase

boiler efficiency 211.7 5

2

TG-1&2 ACC internal Fins cleaning carried out

through HP pump water pressure to reduce ACC

fan power consumption

41 2.2

3 APH tube change to improve APH efficiency &

reduces PA fans Auxiliary power 2.6 5

4 Instt Air used as service air 6.2 0.2

5 Replacement of Start-up vent 14.1 4.6



Saving Achieved

(Rs. Lacs)

Investment

(Rs. Lacs)

6 VFD in Inst. Comp & PID Logic Operation 12 7.2

7 Use of efficient LED lighting in place of

conventional lamps. 1.8 9.3

8

Improvement of Boiler-1 Efficiency by increasing

Petcoke percentage by weight in fuel mix from

11.3 to 46.1%

223 0.5

Sub Total 512.4 34

Grand Total 1183.6 137.9



Without

Investment

Rs. 5.54 Cr.

With

Investment

Rs. 11.84 Cr.

Total Saving-

Rs. 17.38 Cr.

+

Savings / Cost Reduction


Plant Performance Over the Years


Sustainable Plant Performance

4.80

4.00 3.68

2014-15 2015-16 2016-17

GOOD

23.3 %

reduction

56

78 73

2014-15 2015-16 2016-17

Power Cost (Rs./Kwh)

PLF (%)

13.10 10.80 10.20

2014-15 2015-16 2016-17

Aux. Power Cons.(%) GOOD

22.1 %

reduction

3560

3172 3040

2014-15 2015-16 2016-17

Heat Rate (Kcal/Kwh) GOOD

14.6 %

reduction

GOOD


Comparison with Group & Cluster Units and Benchmark

3007 2998 3041 3044 3045

3067 3080 3118

3143 3144 3187

Benchmark VC KCW SCW Sanghi AC GCW APCW RC RWCW ACW

Plant Heat Rate (Kcal/kwh) (2016-17)

6.53 9.00 10.00 10.10 10.20 10.70 11.10 11.30 11.40 11.70 11.70

Benchmark KCW APCW RC SCW ACW AC GCW Sanghi VC RWCW

Aux. Power Cons.(%) (2016-17)


Innovative Projects


Project-1 # Conversion of AFBC Boiler to CFBC

Non utilization of high LOI (Loss on ignition) fly ash in Cement Plant

Disposal of fly ash Low boiler efficiency thus high Power generation cost

Fugitive dust emission, land contamination etc. while disposal

Challenges

Losses

(Total Fly ash generated=86MT/Day)

Loss in terms of fuel

40 MT due to High LOI

(Loss: Rs. 2.2

Lakh/day)

No use of fly ash in

cement manufacturing

(Loss: Rs.0.30 Lakh/day)

Environment pollution

(Loss: Fugitive emission

and EHS)


Before After

Brain Storming & Modification



Utilization of 100% of fly ash of

AFBC Boiler in Cement

Manufacturing

Improved AFBC Boiler efficiency

from 82.4% to 88.1%

Elimination of Fugitive dust

emission by using the ash in

Cement Plant

Reduced Auxiliary power

consumption by 246 kWh/day

Final Outcome

Description

Saving

(Rs.

Lac/Day)

Saving

(Rs. Lac/

Annum)

Fuel 2.2 744

Ash utilization in cement

0.3 111

Aux. Power

0.01 3

Lime Stone

0.1 26

Total Saving 2.6 884

Converted Threat into Opportunity



Objectives:

Reduction in Power Generation cost.

Conservation of Natural resources i.e. Coal/Lignite

Boilers were designed on Lignite/Imported Coal as a

performance fuel.

Available coal cost Rs/MCV is higher compare to Petcoke.

Available Lignite coal having high moisture about 25 to 35 %

which reducing boiler efficiency.

During firing of Petcoke facing issue of Volatile matters & ash

content

SO2 emission was limiting the Petcoke Consumption.

Problem /Background:

Project- 2 # 90% Petcoke Firing in Boilers with Lime Pre-Mix


Analysis:

Initiated Brain storming and no. of suggestion identified. One suggestion was

pre mixing of crushed lime stone in coal at belt to improve VM (due to 30%

LOI in Lime) and ash content which interns reduction in GCV of Mixed fuel.

Modification:

Erected one new discharge chute (size 20’’) with manual isolation gate from

Lime screen discharge chute which divert lime stone in coal feeding

conveyor belt.



Results : Productivity- Increased Boiler Efficiency and safe operation.

Innovation- Now we are transferring the Petcoke with lime stone from

common belt conveyor.

Sustainability- Due to increasing of Lime feeding Sox control well within

limit

Total Cost Saving is 9.85 core/Annum

Intangible Benefits: With this modification we have been able to defer

the Capex project of FGD of Rs. 55 Cr.

During Petcoke permission trial emissions were well within limits and

same has appreciated by GPCB



Opportunity:

Increase in Boiler Efficiency through reduction in Boiler LOI from 10.5% to

3.5%.

BACKGROUND OF THE PROJECT

During using of high GCV Fuel like Petcoke & SA-B and ash from AFBC

Boiler, CFBC Boiler LOI has been increased and unable to use the whole fly

ash in Cement Plant.

A project has been taken to reduce the LOI in CFBC Boiler

Approach:

Brain Storming

Idea Generation

Data Collection and analysis

Project on LOI

Project-3 # Reduction in LOI of CFBC Boiler


Money

Method/Process Material

Machine Man

High Fly

ash LOI

Analysis of Crushed Coal size

Coal crushing operation

Gap of Crusher

Screen size of coal

Coal quality

Skill

knowledge

Training

Lower boiler eff.

Improper Air flow Ratio

CAUSE & EFFECT DIAGRAM

Higher Fines in Coal


Not aware about LOI

High Furnace Draft (-25

to -35mmwc)


SN Causes Action Taken

1 Size of Coal i.e. Higher

fines in coal

Adjust the impactor Gap for proper Fuel

on fortnightly basis.

2 Improper Air Flow Optimized the air flow ratios i.e. Primary

air Vs secondary air Vs tertiary air

3 Monitoring of coal size,

GCV and ash

Analysis of coal started on shift basis and

maintained the coal size within range.

4 Low retention time due to

High furnace draft

(-25 to -35 mmWC)

Discussed with OEM and optimized the

furnace draft in between -10 to -15

mmWC)

5 Engineers were not aware

about LOI of their shift

Analysis started on shift basis twice and

training given to them



1%

3%

5%

7%

9%

11%

1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31

September-2016 October-2016 November-2016

Results :

Reduction in Fly ash LOI by 7%

Increment in Boiler Efficiency by 1.8%

Saving of Rs. 45.2 Lacs

Utilization of 100% fly ash in Cement Plant

LOI Trend



Project - 4 # Optimize Operation of BFP pumps

Opportunity -Whenever Boiler Load exceeds beyond 55 % load (designed 2*55%)

then 2nd Boiler feed pump to be started to maintain boiler drum level. Due to

same APC increased.

Analysis - Boiler Load increased beyond 55 % load with single Boiler Feed Pump

and check its Motor KW, Full load current, pump parameter & pump curve and

stabilize single BFP up to 80% Boiler load and starting 2nd BFP above 80 % load.

Implementation- For sustainable operation, BFP auto start logic implemented

with discharge pressure to start 2nd BFP

Saving of Power : 5952000 Kwh/Annum

Tangible Saving : 208 Lac Rs./Annum


Sustainability Initiatives


GtG energy consumption status (Cement & Power Plant)

1223 1104 1148.57 1063.7

0

500

1000

1500

2014-15(Baseline Year)

Target SEC for PAT-2 cycle(04/16 to 03/19)

2015-16 2016-17

Gate to Gate Sp. Energy Cons. (Kcal/Kg PPC)

Unit registered as Designated Consumers (DC) under PAT-2 scheme

Target given for 7.57 % reduction in GtG Specific Energy

Consumption at the end of PAT-2 cycle (2016-19)

Implementation of Encon projects in the unit reflects 13.01 %

reduction in SEC at the end of 2016-17 without normalization.


GHG Emissions in MT/Yr (Cement & Power Plant)

1928754 1743246 2319407

2014-15 2015-16 2016-17

GHG Emission Over All Plant (Incl. Cement Plant)

221480 267746 251163

2014-15 2015-16 2016-17

GHG Emission TPP


2000

112500

50418

FY14-15 FY15-16 FY16-17

Lawn

Developed

(SQF)

3410

7722

6241

FY14-15 FY15-16 FY16-17

Tree

Plantation

(Nos.)

Green Belt development At TPP


84 91

945

69 238

182

470

143 18

CSR Desal

Drinking+ Service Civil

TPP Fire + Hort.

Clinkerisation Cement mills

DG

103 38

808

13

187

55

282

164 29

CSR Desal

Drinking+ Service Civil

TPP Fire + Hort.

Clinkerisation Cement mills

DG

Total 1679 Kl/day

FY’16 FY’17

Reduction in Water Consumption by 561 KL /day (23% Reduction)

(From 0.39 to 0.28 Kl/MT of Cement)

Water Consumption Reduction

Total 2240 Kl/day


Water Harvesting for water positive


Waste Utilization

SN Type of Waste Quantity

1 Black carbon as a alternate fuel 1800 MT

2 TPP Fly ash and bed ash Utilized in

Cement Manufacturing 26000 MT

3 TPP N-pit Water Utilized for dust

suppression and ash quenching 35025 M3


Energy Cell


Methodology adopted for Energy Monitoring

Energy management cell headed by FH-TPP.

Daily monitoring of PLF, Heat rate and Aux. power deviation.

Analysis of equipment performance for deviation.

Identification of energy conservation scope through - Loss Cost Matrix, Brain

Storming and Theme base suggestions/Kaizens scheme under “Energy Saving ”.

Feasibility study of suggestions & submit proposal for sanction.

Preparation of detail action plan.

Monthly review to monitor project progress.

Benefits analysis after project implementation.

Sustainability of the project


Energy Monitoring

Efficiency Energy

TPP Daily Report 27-Aug-17

Today MTD Parameters Units Unit-1 Unit-2 Total Unit-1 Unit-2 Total

A Plant Performance 1 Avaialbility Factor % 100.0 100.0 100.0 100.0 100.0 100.0

2 STG Running Hours Hrs 24.00 0.00 24.0 648.00 0.00 648.0

3 Plant Load Factor % 0.06 0.00 0.06 0.07 0.00 0.07 4 Gross Generation MWh 512 0 512 15194 0 15194

5 Aux Consumption MWh 43.0 0.0 43 1444.3 0 1444 % 8.39 0.00 8.39 9.51 0.00 9.51

6 Shut Down Power Kwh 0 2224 2224 0 68938 68938

Aux. power including SD

% 8.39 0.00 442.77 9.51 0.00 463.22

7 Net Generation MWh 469 -2224 -1755 13750 -68938 -55188 8 Average Load MW 0.02 0.00 0.02 0.02 0.00 0.02 9 TG I/L Steam MT 2191 0 2191 64699 0 64699 a Steam from Boiler MT 2191 0 2191 64699 0 64699

10 Sp. Steam Cons kg/kwh 4.28 0.00 4279.30 4.26 0.00 4.26

11 Turbine Heat Rate Kcal/Kwh 2615 0 2614650 2599 0 2599

12 Station Heat Rate Kcal/KWH 2966 0 2966 2946 0 2946

13 SFC Kg/Kwh 0.46 0.00 0.46 0.61 0.00 0.61

14 Vacuum Kg/Cm2 -0.78 0.00 -0.78 -0.78 0.00 -0.78

B Generation Cost

1 On Gross Gen Rs/Kwh 2.86 0.00 2.86 2.59 0.00 2.59

2 On Net Gen Rs/Kwh 3.12 0.00 -0.83 2.86 0.00 -0.71


Improvement Projects/ Kaizens/ Suggestions

Kaizen per Employee

4.8

7.8

9.4

2014-15 2015-16 2016-17

Employee recognition


Implementation of corrective /

Preventive action


OHASA18001:2007

ISO 14001:2015

ISO 9001:2015

Applied for 50001

System Accreditation in 2016-17…..


S.No. Non-conformity Description Corrective Action Taken

1 In Quality objectives / targets, plant

performance ( production , operational

ratio) indices are construed as ‘Quality

objectives’ which has not been properly

linked with the quality aspects to meet

customer requirement

All parameters of IMS Objectives

(FY 2016-17) is reviewed and

aligned as per requirements.

2 Quality objectives / Targets are not

stretched / re-fixed to keep continual

improvement of processes based on

objective measurement, even achievement

overshoots (e.g. PR to PO lead time, PM in

Raw mill stack, etc.)

Departmental Objectives &

targets of FY 2016-17 is

reviewed and set the stretched

target against performance

parameters

3 The organization shall establish, implement

and maintain documented environmental

objectives and targets, at relevant functions

and levels within the organization. Energy /

heat conservation is one of EMP activities

only mapped at macro level without

connecting the same with plant / sectional

micro-level activities which are in practice.

While issuing the new

Management Programme (MP), it

is ensured that activities of MP

are mapped at section level

activities.

Implementation of Corrective & Preventive Actions


Best practices/ Team Work/ Knowledge

Sharing


Best Practices

Examples are as under –

Energy monitoring system installation for better analysis of Aux.

Power consumption

Impact analysis in bearing by vibration spectrum analysis

technique for lubrication of equipment

Energy efficient motors & Illumination System

AFBC boiler converted into CFBC boiler to reduce fly ash LOI

100% ash of boiler, utilized for Cement Manufacturing .


Team Work in EnCon

SN EnCon idea *

Idea

originated

in FY **

Extent of man-power

involved ***

Progress of

implementation

1

Closed Loop operation of VFD

operated ACW pump operation with

discharge pressure

2015-16 O&M ,E&I & M/S-ABB

Team Completed

2

Closed Loop operation of Boiler Feed

pump operation with discharge

pressure

2016-17 O&M and E&I Team Completed

3 Bed Ash cooler exhaust gas diverted

in APH O/L duct to save energy 2016-17 O&M and M/S TKIL Completed

4

Closed Loop operation of VFD

operated CEP pump operation with

discharge pressure

2016-17 O&M ,E&I & M/S-ABB

Team Completed

5 Closed loop operation of Pet coke

fuel feed in boiler 2016-17 O & M and E&I Team Completed


Stronger supplier relationship -Vendor Meet

Identification improvement projects with vendors.

Development of better supplier – customer partnership


Knowledge Sharing with Group Units / Vendors

Kaizen Souvenir shared to all Group Units.

Conversion of AFBC Boiler to CFBC horizontally replicated to other

Group Units.

Shared Erosion protection Plate modification to M/s ThyssenKrupp

Bed ash handling of AFBC Boiler through Primary Air fan in place of

Compressed air shared with M/s ISGEC

Provision of MCB before signal isolator in VFD shared with M/s ABB


Corporate Social Responsibility

Education

Sustainable Livelihood

Social Causes

Infrastructure Development

Health Care

Corporate CSR

CSR Vision

CSR Policy

Focus Area


Glimpses

Fodder support to village panchayats

Drinking water supply to villages.

Cattle vaccination camp


Awareness campaign for Personal

hygiene, Family planning,

Immunization camps.

Awards to best students nearby

Villages.

Corporate Social Responsibility


Awards & Accolades


Awards & Accolades

Ramkrishna Bajaj National Quality Award to SCW FY’16-17


Awards & Accolades

1ST Prize in Mining Machinery

Improvement & Innovations

2nd Prize in Mine working &

Implementation of 10th / 11th

Conference

3rd Prize in Raising by Explosives ,

Storage & Transportation / Raising by

Surface Miner

2nd Prize in Best Stall at Mines Safety

Week Final Day Celebration.


Way Forward


Energy Saving Projects

SN Energy Saving projects Proposed Saving

Per Annum Target date

1 Installation of 5 MW solar Power Plant Mar’18

2 Erection & Commissioning of Turbo Charger

System 1851207 Kwh Dec’17

3 Modification in ACC 213840 Kwh Nov’17

4 MV drive installation for Boiler Feed pumps 1320000 Kwh Sep’17

5 High Efficiency pump installation in BFP 79200 Kwh Dec’17

6 High Efficiency pump installation in ACW 158400 Kwh Dec’17

7 TPP#1&2 Main steam & Feed Water line

interconnection Rs.139 Lacs/Yrs. Nov’17

8 Low capacity CEP installation 79200 Kwh Oct’17

9 Energy efficient FRP ACC fans 950400 Kwh Feb’17


Team Sewagram Cement Works

JOURNEY TOWARDS

EXCELLENCE CONTINUES.……

ultratech cement limited -...

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